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Thermal Processing in the Fertilizer Industry

GEA Barr-Rosin


Thermal Processing Systems
GEA Barr-Rosin has extensive experience in the design, manufacture and installation of a range
of thermal processing equipment for the Fertilizer Industry. We have supplied numerous units
to leading producers throughout the world. Designs are based on in-house ‘know-how’ as well as
licensed technology:
Unit operations include:
• Granulation / Conditioning
• Drying
• Cooling
• Coating
• Holding / Ageing
• Thermal cycling
• De-dusting
Fertilizers and intermediate materials
processed include:
• Potash
• Phosphate Rock
• Monoammonium Phosphate (MAP)
• Diammonium Phosphate (DAP)
• Triple Super Phosphate (TSP)
• Granular Triple Super Phosphate (GTSP)
• Ammonium Nitrate (AN)
• Ammonium Sulphate
• Calcium Ammonium Nitrate (CAN)
• Compound Fertilizer
• NPK

• Urea
• Proprietary Formulations
Tailored Systems
All GEA Barr-Rosin systems are tailored to our customers’ needs.
Each application is carefully considered and the best solution is
provided based on pilot plant test results when required and
taking full account of product and site requirements.
GEA Barr-Rosin’s strength lies in custom-designed technology
based on Research & Development efforts and Pilot Plant trials.
With a fully operational Pilot Plant facility in-house in
Broisbriand, Quebec, Canada, equipment designs could be
proposed according to specific operating conditions and process
behavior to optimize process flow and operation. Particular
attention could also be paid to energy-savings through
recuperation and/or equipment integration.
GEA Barr-Rosin is a leading supplier of thermal processing
equipment. Previous experience in the fertilizer industry has
enabled GEA Barr-Rosin to develop a range of technologies
for fertilizer applications, including fluid bed dryers/coolers/
de-dusters, rotary dryers, conditioning/polishing/coating drums,
contact column coolers, and flash and ring dryers.

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Fluid Bed
GEA Barr-Rosin Fluid Beds are
increasingly used for a broad
range of fertilizer products.
Capital cost, size and weight
are reduced compared with

conventional systems. Drying
and cooling time is also shorter
as the high heat transfer
coefficient is achieved in the
fluidized state. The process is
gentle enough for crystals to
prill or for minimizing granule
abrasion. Fluid Beds can also be
designed to elutriate fines from
the product if required. We
have supplied numerous units
throughout the world with
capacities of up to 780
tons/hour.
Combined drying and cooling can also be achieved in a single unit
with two fluidizing zones, with the option of exhaust air recycle,
which significantly reduces energy consumption and off-gas
volumes. Hot air is supplied to the first zone and ambient or
conditioned air to the second zone.
Rotary
The Rotary Cascade Dryer and Cooler are widely used in the
fertilizer industry. The robust yet simple construction combines
flexibility and reliability, enabling it to operate continuously
under the arduous conditions experienced in fertilizer factories.
Moisture or heat is removed by showering the fertilizer granules
or prills through a hot gas, ambient or conditioned air stream
flowing in either a co-current or counter-current direction. Heat


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transfer, product distribution and efficiency are influenced by the
internal design, while the long but variable retention time
governs the rate of water diffusion or degree of cooling.
Granulation drums, with flexible internal rubber panels,
ammoniator and sparge pipework can also be supplied, along
with coating or conditioning drums for production of controlled
release fertilizers.
Contact Column Cooler
The GEA Barr-Rosin Contact
Column Cooler has been
developed in response to the
ever increasing stringent
environmental specifications.
Product cooling is frequently
used to permit handling and
prevent caking of fertilizer
during storage, especially
in hot and humid climates.
The Column Cooler operates
on the principle of gravity, the
fertilizer slowly descending in
plug flow through a column
incorporating
bundles
of cooling
tubes, through
which cooling
water flows.
The tube bundles
are arranged in

separate sections which allows
the unit to be configured for specific thermal duties, both
by means of physical bundle geometry and if advantageous,
independent water flows and temperatures.

Flash and Ring Dryers
Pneumatic flash dryers are used with products that dry rapidly
due to the easy removal of free moisture or where any required
diffusion to the surface occurs readily. Drying takes place in a
matter of seconds. Wet material is mixed with a stream of heated
air (or other gas) which conveys it through a drying duct where
high heat and mass transfer rates rapidly dry the product.
Applications in the fertilizer industry include products of fine
grades and particle sizes, the drying of filter cakes, crystals,
granules, pastes, sludges and slurries; in fact almost any material
where a powdered product is required. Proper feed conditioning
is the key to drying materials with high initial moisture contents
which could be achieved by using twin shaft paddle mixers.
As the drying air also conveys the product, this system can be
used to discharge at elevation. Product is separated from the
drying gas in either single or multi cyclones, and/or bag filters.
Sometimes cyclones are followed by scrubbers for final cleaning
of the exhaust gases.
The Ring Dryer employs the same basic principle as the flash
dryer in that the material to be dried is dispersed and conveyed
through the dryer in a hot air stream. However the Ring Dryer
incorporates a centrifugal classifier which allows selective
internal recirculation of solids, effectively lengthening the
retention time of larger particles in the dryer, while finer material,
which dries more rapidly, exits the dryer with the exhaust air.

Internal recycle also provides additional feed conditioning by
reintroducing dry material to the feed point.

The design may also incorporate a small counter-current upward
air flow (conditioned as necessary) to carry away residual
moisture.
The GEA Barr-Rosin Contact Column Cooler has no moving
parts other than feed and discharge conveyors and water / air
circulation equipment. It is both an ecological and economical
solution.

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GEA Group is a global engineering company with multi-billion euro sales and operations in more than
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process technology. GEA Group is listed in the STOXX® Europe 600 Index.

GEA Barr-Rosin
GEA Canada Inc., Barr-Rosin Division
92 Prevost Street, Boisbriand, Quebec J7G 2S2, Canada
Tel : +1 (800) 561 8305, Fax: +1 (450) 437 6740
Email:
GEA Process Engineering Inc., Barr-Rosin
1600 O‘Keefe Road, Hudson WI, 54016, United States
Tel : +1 (800) 561 8305, Fax: +1 (450) 437 6740
Email:

www.gea.com

GEA Process Engineering Ltd., Barr-Rosin Division
48 Bell Street, Maidenhead, Berkshire, SL6 1BR. United Kingdom
Tel +44 (0)1628 641 700, Fax +44 (0)1628 776 118
Email:

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GEA Process Engineering